This document provides a case study on Tata Power's efforts to increase the sustainable use of bottom ash, a byproduct of coal combustion. It details the quality circle team's application of the PDCA (Plan-Do-Check-Act) process to address the problem of disposing 625 metric tons of bottom ash per month. Through root cause analysis, trials, and regular implementation, the team developed a solution to incorporate bottom ash into bricks, reducing monthly disposal to 300 metric tons. Tangible benefits included savings of over Rs. 4 lakhs in transportation costs and Rs. 18 lakhs in natural sand costs. Future plans aim to further reduce disposal and deploy the approach across Tata Power.

1. Bombay Chapter of
Commerce
Sustainability Case Study
MET Institute of Management ,Mumbai
Team: Blaze
Shruti Railkar btshruti@gmail.com +91 9969004297
Kunal Thakur kunal68@gmail.com +91 8879118457

2. First time Bottom Ash
used in Bricks
by
QC Team TATA Power
Philanthropy without scale and sustainability is like any other bad
business that will simply wither and die on the vine.
-Naveen Jain
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3. Our Approach
Company Analysis
PDCA Cycle
Benefits
Future Plans
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4. Company Analysis
PDCA Cycle
Benefits
Future Plans
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5. Company Analysis
PDCA Cycle
Benefits
Future Plans
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6. Company Analysis
PDCA Cycle
Benefits
Future Plans
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7. • To be the most admired and responsible Integrated Power Company with
international footprint, delivering sustainable value to all stakeholder.
VISION
• We will become the most admired and responsible Power Company
delivering sustainable value by:
• Operating our assets at benchmark levels
• Executing projects safely, with predictable benchmark quality, cost and time
• Growing the Tata Power businesses, be it across the value chain or across
geographies, and also in allied or new businesses
• Driving Organizational Transformation that will make us have the conviction
and capabilities to deliver on our strategic intent
• Achieving our sustainability intent of ‘Leadership with Care’, by having
leading and best practices on Care for the Environment, Care for the
Community, Care for the Customers and Shareholders, and Care for the
People
MISSION
Company PDCA Cycle Benefits Future Plan
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8. TOTAL GENERATION CAPACITY 6999MW
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Company PDCA Cycle Benefits Future Plans

9. QUALITY CIRCLE TEAM
QC
TEAM
UW Gaikwad
LEADER
Priyanko
Majumdar
Rambhau
Rekhate
AB
Suryavanshi
Prashant
Rane
FACILITATOR
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Company PDCA Cycle Benefits Future Plans

10. PROBLEM SOLVING CONTENTS
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11. STEP 1: Identification of problem
BRAINSTORMING
TOTAL NO OF
PROBLEMS
IDENTIFIED=60*
*List of problems provided in appendix
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12. STEP 2: Selection of Problem
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13. Selection Of Problem
The problems were categorized in A,B,C categories (A,B,C
analysis)
A category-Which can be solved by QC circle
B category-Which can be solved by other department
C category-problems which require management approval
A
68%
B
17%
C
15%
Percentage
Category A = 41
Category B = 10
Category C = 9
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14. Selection Of Problem
QC TEAM DECIDED -CATEGORY A STRATIFICATION
A CATEGORY
Environment :
4
Safety/Health
: 13
Cost:6Moral:6
Quality :12
Selection Of theme
Sustainability/environment was selected since plant is
located in heart of Mumbai city which is densely
populated
• Slide 2 of 59
Directly linked to MISSION statement
Environment
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15. STEP 3: DEFINING THE PROBLEM
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16. Defining The Problem
Reason
• In Trombay Thermal Power Station, Coal is used as major fuel for Power generation .
• Ash is a byproduct
Type
• Fly Ash-which is total burnt coal and which resale to Cement construction company
• Bottom Ash –No resale value. Therefore we have to dispose it off.
% Content
• The total % of Ash is divided in to two parts i.e. around 80% Fly Ash & 20% Bottom Ash
Requireme
nt
• Coal requirement for Trombay is around 9000 MT per day.
Company PDCA Cycle Watch Industry Marketing strategy Cost analysisCompany PDCA Cycle Benefits Future Plans
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17. Defining The Problem
Ash
• They are using good quality Imported Indonesian coal, it contains around 1-2%
of ash content.
Content
• Bottom Ash Generated: 7500 MT/yr. (625 MT/month)
• Fly Ash generates: 37500 MT/year.
Future
• After conversion of U#6 from Oil to coal, Bottom ash generation may increase by
5000 MT/year
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18. Defining The Problem
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19. Defining The Problem
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20. Environment pollution
Huge amount disposable bottom ash 625 T/month(65trucks)
Disposable at the distance of 30KM
People have to work at night since transportation is at night.
Expenses Incurred on transportation 3,00,000/- month
Lack of space for storage Bottom ash.
Affect Green Manufacturing Index(GMI)4
Defining The Problem
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Company PDCA Cycle Benefits Future plans

21. As per Central Electricity Authority of India ‟Per Megawatt(MW) area calculation
required for imported coal is:0.47Acre/MW
But our plant is running/installed at the ratio of :0.27Acre/MW (Situated in Mumbai
(Metro city)
Already they are running their plant with lesser area.
Cleanness/healthiness or up keeping of the plant area got affected due continues
storage of the Bottom within plant area.
Also as per MOEF (Ministry Of Environment & Forest ) notification we can store the
Bottom Ash(solid waste) upto:3Months only
Defining The Problem
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22. Defining The Problem
To Improve:
•Green Manufacturing Index (GMI) . (Directly linked to Companies “MISSION”)
To reduce
Environment
pollution
Storage &
Transportation
problem
Expenses
incurred for
disposable of
bottom ash
Working at
night shift
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23. Defining Of Problem (Goal setting)
Disposing at present
(MT/Month)
Planned disposal
(MT/Month)
Bottom ash in MT 625 300
0
100
200
300
400
500
600
700
BottomashInMT
Bottom ash in MT
To reduce disposable of bottom ash from 625MT/Month to 300MT/Month
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24. STEP 4: Analysis of Problem
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25. ANALYSIS OF PROBLEM 5W & 1H TOOL
What?
•625MT/month-transportation
•Around Rs.3.2 Lakhs per month expenses
Where?
•Plant situated at trombay in Mumbai
•Transported outside the plant area as permitted by MPCB(Maharashtra pollution control board
When?
•Ash generated 365 days of the year
•Transportation in late hours
Who ?
•Problem is irrespective of person –Process related
How?
•Transported at late night by dumpers .
•Spillage
•Environmental pollution
Summery of SAP report
Year Bottom ash qty in
MT/year
Amount spent for
disposal in lakhs
2007-08 7000 35
2008-09 8600 44
2009-10 7500 40.5
2010-11 7350 37.5
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26. Step 5: Identification of causes
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27. Identification Of Causes
Environment Person System Material
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28. Identification Of Root Causes
By Why-Why Analysis
Ash Content in
100% pure
coal is not
available
Available from
natural mines
Why ?
Why ?
Coal
Economically &
easily available
than Oil & Gas
Why ?
Transportation
By Road
Disposal yard is
30KM away
from plant
Only MPCB
approved
dumping yard
Why ?
Why ?
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29. Identification Of Root Causes By Why-Why
Analysis
Space constraint
More generation in small
space
Generation has been increased
from 180MW to1580MW
Need for power
Industrial growth
Dumping
Environmental Constraint
Mumbai (Metro city)
Today TATA power have
dumping permission but they
are not sure about tomorrow
Why ?
Why ?
Why ?
Why ?
Why ?
Why ?
Why ?
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30. STEP 6: DATA ANALYSIS
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31. Data Analysis
Total amount spent
in last 4 years- 157 lakh
Avg amt spent till date-39.25 lakh/yr
Total Bottom Ash disposed-
30450MT(FOR LAST 4 YRS)
Avg bottom ash disposed-7612 MT/yr
SAP REPORT
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32. Data Analysis
Disposal area is far away from plant 30 km
• Bottom ash needs to be disposed at MPCB approved
are
Ash Content in a Coal
• Indian coal has 30-40% ash content
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33. STEP 7: DEVELOPING SOLUTION
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34. Some of the solution listed down
Sr No Description Statement Remark
1
Use of other fuels like gas/oil instead
of coal
Coal is economical
than other fuel
Rejected
2
Transfer the plant at a remote
location
Very costly. Not
possible at this
moment
Rejected
3 Use of 100% pure coal
Got the coal from
natural mines. 100%
pure coal not
available
Rejected
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35. Developing Solution
Possible usage of bottom ash
Non structuring work like PCC, Plastering
Leveling Bed for Paver blocks
Molding of bricks
Paver blocks
Structural/Masonary work
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36. STEP 8: TRIAL IMPLEMENTATION
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Company PDCA Cycle Benefits Future plans

37. Developing solution
Sr. No Solution Statement Remark
1
PCC and
plastering work
We can replace
bottom ash
instead of sand in
the PCC & plaster
Selected
2 Bottom Ash Bricks
As per result we
can use it Bricks
Selected
3
Leveling bed for
paver block
We can use it for
leveling of paver
block
Selected
4 For masonry work
Ash can be used
instead of sand
Selected
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38. TRIAL IMPLEMENTATAION
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39. TRAIL IMPLEMENTATAION
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40. Trial Implementation
Sample
No
Ratio
(by volume)
Proportion Weight
(KG)
Strength
Cement Bottom Ash %
(Kg/brick)
Fly
Ash
Stone
Dust
MPA
(N/mm2)
1 1:4:6 7.5% 42.50%(1.35) 50% Nill 4 7.52
2 1:5:4 8.6% 51%(2.04) 40.4% Nil 4 15.64
3 1:6:3 8.6% 61.13(2.44) 30.29
%
Nil 4 11.70
4 1:8:3 7.12% 67.71%(2.84) 25.16
%
Nil 4.2 11.4
5 1:8:2 7.18% 73.91%(2.83) 18.31
%
Nil 3.8 15.67
6 1:10:3 6.1% 72.4%(2.78) 21.5% Nil 3.84 6.24
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41. Comparison Between Clay Brick & Bottom
Ash Brick
Sr No Property Clay Brick Bottom Ash
Brick
Remark
1 Compressive
strength
5-6MPA 15-16MPA 3 time more
2 Density 1800-1900
Kg/cm2
1900-2000
Kg/cm2
Acceptable
3 Water
Absorption
10-20% 10-20% Ok
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42. STEP 9:REGULAR IMPLEMENTATION
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43. REGULAR IMPLEMENTATION
• During trial implementation it was confirmed that we will continue with the proportion 1:8:2
having an un expected strength value of 15.67MPA.
• Decided, we will implement the trial proportion 1:8:2 on regular basis.
• Consumption of Bottom Ash per Brick is 2.83KG.
• 250 bricks per Day.
• We have increased our brick molding from 250 bricks/day to 350 Bricks/day.
• Utilizing 990KG Bottom Ash daily for molding of 350 Bricks.
• Bottom Ash Consumed for PCC work per meter cube (M3) = 765KG
• (APPENDIX-84)
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44. Regular Implementation
Bottom Ash Brick
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45. TROMBAY PLANT AREA
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46. TANGIBLE BENEFITS
Cost Benefit Analysis:
• After installation of Pilot Brick plant Bottom Ash is used in making of Bricks, PCC (Plain cement
Concrete), Plaster & masonry work and curbing work for all new Gardens developed - total Bottom Ash
Consumed within 6 and half month = 875 MT (Metric Ton)
• Saved the transportation cost for 875 MT
• Transportation and Disposal cost of Bottom Ash per Ton is Rs. 510.
• Direct saving in the transportation cost of Bottom Ash = 875 X 510 =4,46,250/-
• As we had replaced the natural sand by using Bottom ash, we saved the cost of procuring Natural Sand
for 875 Metric Ton.
• Cost of 1 Ton sand = 2100/- (if easily available, but now a day‟s natural sand is not easily available)
• Cost of 875 Metric Ton Sand saved = 875 X 2100 = 18,37,500/-Saving due to utilization of Bottom Ash
instead of Sand in Bricks and civil work i.e. if we had
purchased the sand for above work we would have to spend around: Rs. 18,37500/
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47. INANGIBLE BENEFITS
Care of Environment &contribution to wards sustainability:
• As in this project we are able to reduce the storage and disposal problem of Bottom Ash.
• Reduction of pollution in transport of Bottom Ash
• Reduction in fuel cost and saving precious resources (diesel) for the transport of Bottom Ash
, Bricks & natural sand.
• Reduction in carbon foot print of the company.
• Fatigue of workers reduced in the transportation of Bottom Ash , Natural sand and Bricks.
• Reduction in mining of natural sand
• Reduce, Reuse and Recycle .Contribution to wards Greenolution . Reusing the Bottom Ash in Civil
work.
• Team work Experience As a team we worked together to achieve our goal.
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48
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48. FUTURE PLAN
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49. Future Plan
To achieve our goal of reducing disposal of Bottom Ash from 625 MT/months to 300MT/month &
zero disposal by 2020 following are the future plans:
•Taking Clearance for the Radioactivity test to use the Bottom Ash Bricks for Structural and in-
house. work : Samples submitted on 12/10/12 to BRIT office (Department of Atomic Energy,
Radio analytical laboratory , Govt. of India, Mumbai ) for testing . Waiting for the results.
•Installation of Large capacity Brick plant having the capacity around 2000 to 3000 numbers of
bricks per day.
•Utilization of Bottom Ash for the structural use.
•Making of Paver blocks by using Bottom Ash.
•After successful implementation of above plans we can reduce our Bottom Ash disposal to
300MT/months within next two years.
•Horizontal Deployment all over the TATA POWER.(Already Started)
•100% Utilization by 2020.
•Will be one of the future economical and eco-friendly construction materials
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50. Thank you!!
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51. APPENDIX
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52. Appendix
60 problems
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53. Contd….
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54. Contd…
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55. Selection of Problem-RATING METHOD
0
20
40
60
Problem
3
Problem
5
Problem
17
Problem
34
Rating
Rating
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56. Appendix
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